Scheduling

Lokesh Vijayvargy

SCHEDULING
DETERMINATION OF WHEN LABOUR, EQUIPMENTS AND FACILITIES ARE NEEDED TO PRODUCE A PRODUCT OR PROVIDE A SERVICE SCHEDULING IS THE LAST STAGE OF PLANNING BEFORE PRODUCTION JOB SHOP PRODUCTION SCHEDULING & EMPLOYEE SCHEDULING

Scheduled Operations
Process Industry Linear programming EOQ with noninstantaneous replenishment Mass Production Assembly line balancing Project Project -scheduling techniques (PERT, CPM) Batch Production Aggregate planning Master scheduling Material requirements planning (MRP) Capacity requirements planning (CRP)

OBJECTIVES OF SCHEDULING

REDUCING JOB LATENESS MINIMISE COMPLETION TIME MINIMISE OVERTIME IMPROVE LABOUR/MACHINE UTILISATION MEETING CUSTOMER DUE DATES MINIMISE IDLE TIME MINIMISE WORK-IN-PROCESS INVENTORY MINIMISE RESPONSE TIME MINIMISE FLOW TIME.

SHOP FLOOR CONTROL (SFC) IS THE

SCHEDULING AND MONITORING OF DAY-TOPRODUCTION IN A JOB-SHOP.

LOADING: CHECKING THE AVAILABILITY OF

MATERIAL, MACHINES AND LABOUR ASSIGNING WORK TO INDIVIDUAL WORKERS OR MACHINES AND LOAD LEVELLING. THE PROBLEM OF DETERMINING HOW BEST TO ALLOCATE JOBS TO MACHINES OR WORKERS TO TASKS CAN BE SOLVED BY ASSIGNMENT METHOD OF LOADING.

Assignment Method
1. Perform row reductions 4. If number of lines equals number of rows in matrix then optimum solution has been subtract minimum value in each found. Make assignments where zeros row from all other row values appear 2. Perform column reductions subtract minimum value in each 5. Else modify matrix subtract minimum uncrossed value column from all other column from all uncrossed values values add it to all cells where two lines 3. Cross out all zeros in matrix intersect use minimum number of other values in matrix remain horizontal and vertical lines unchanged 6. Repeat steps 3 through 5 until optimum solution is reached

Assignment Method: Example

Initial Matrix X Y Z A Row reduction 5 4 2 5 0 0 1 1 1 2 0 0 5 4 1 6 1 10 6 7 9 2 5 2 6 5 PROJECT 3 4 6 10 4 6 5 6 4 10 Cover all zeros 3 2 0 3 0 0 1 1 1 2 0 0 4 3 0 5

Column reduction 3 2 0 3 0 0 1 1 1 2 0 0 4 3 0 5

Number lines number of rows so modify matrix

Assignment Method: Example (cont.)

Modify matrix Cover all zeros

1 0 0 1

0 0 3 1

1 2 2 0

2 1 0 3

1 0 0 1

0 0 3 1

1 2 2 0

2 1 0 3

Number of lines = number of rows so at optimal solution 1 1 0 0 1

X Y Z A

PROJECT 2 3 0 1 0 2 3 2 1 0

4 2 1 0 3

X Y Z A

1 10 6 7 9

PROJECT 2 3 4 5 6 10 2 4 6 6 5 6 5 4 10

Project Cost = (5 + 6 + 6 + 4) X Rs100 = Rs 2,100

SEQUENCING
THE ORDER IN WHICH TO PROCESS THE JOBS; WHEN MORE THAN ONE JOB IS ASSIGNED TO A MACHINE OR ACTIVITY. THE PROCESS OF PRIORITISING JOBS = SEQUENCING FCFS (FIRST-COME FIRST-SERVED) / FIFO / LCFS (LIFO) EARLIEST DUE DATE (DDATE) (EDD) ; HIGHEST CUSTOMER PRIORITY (CUSTPR).

Sequencing Rules
FCFS - first-come, first-served LCFS - last come, first served DDATE - earliest due date SETUP - similar required setups SLACK - smallest slack CR - critical ratio SPT - shortest processing time LPT - longest processing time

SEQUENCING
MINIMUM SLACK (SLACK); LEAST SLACK (LS) SLACK = (DUE DATE - TODAYS DATE) - REMAINING PROCESS TIME. SLACK (S/RO) PER REMAINING OPERATIONS

S/RO = (DUE DATE - TODAYS DATE) - REMAINING TIME NO. OF OPERATIONS REMAINING

CRITICAL RATIO (CR) : (SMALLEST)

CR = DUE DATE - TODAYS DATE REMAINING PROCESSING TIME TIME REMAINING WORK REMAINING

IF CR >1, THEN THE JOB IS AHEAD OF SCHEDULE IF CR <1, THEN THE JOB IS BEHIND SCHEDULE IF CR =1, THEN THE JOB IS EXACTLY ON SCHEDULE.

SHORTEST PROCESSING TIME (SPT) / LPT FLOW TIME (COMPLETION TIME): IS THE TIME IT TAKES A JOB TO FLOW THROUGH THE SYSTEM MAKESPAN IS THE TIME REQUIRED TO COMPLETE A GROUP OF JOBS. (= TIME OF COMPLETION OF LAST JOB STARTING TIME OF FIRST JOB) TARDINESS IS THE DIFFERENCE BETWEEN THE LATE JOBS DUE DATE AND ITS COMPLETION TIME

Simple Sequencing Rules

JOB

PROCESSING TIME

DUE DATE

A B C D E

5 10 2 8 6

10 15 5 12 8

SEQUENCING RULES
A) B) FCFS EDD

C)
D) E)

LS
CR SPT

POSSIBLE SEQUENCES : 5! = 120 FOR 5 JOBS

SEQUENCE

START TIME

PROCESSING COMPLETION DUE TARDINESS TIME TIME DATE

A B C D E AVERAGE

Simple Sequencing Rules: FCFS

FCFS SEQUENCE START TIME PROCESSING COMPLETION DUE TIME TIME DATE TARDINESS

A B C D E

0 5 15 17 25

5 10 2 8 6

5 15 17 25 31

10 15 5 12 8

0 0 12 13 23

Simple Sequencing Rules: DDATE

DDATE SEQUENCE START TIME PROCESSING COMPLETION DUE TIME TIME DATE TARDINESS

C E A D B

0 2 8 13 21

2 6 5 8 10

2 8 13 21 31

5 8 10 12 15

0 0 3 9 16

Simple Sequencing Rules: SLACK

A(10-0) 5 = 5 B(15-0) - 10 = 5 C(5-0) 2 = 3 D(12-0) 8 = 4 E(8-0) 6 = 2

TARDINESS

SLACK SEQUENCE

START TIME

PROCESSING COMPLETION DUE TIME TIME DATE

E C D A B

0 6 8 16 21

6 2 8 5 10

6 8 16 21 31

8 5 12 10 15

0 3 4 11 16

Simple Sequencing Rules: CR

CR SEQUENCE START TIME

A(10)/5 = 2.00 B(15)/10 = 1.50 C (5)/2 = 2.50 D(12)/8 = 1.50 E (8)/6 = 1.33
TARDINESS

PROCESSING COMPLETION DUE TIME TIME DATE

E D B A C

0 6 14 24 29

6 8 10 5 2

6 14 24 29 31

8 12 15 10 5

0 2 9 19 26

Simple Sequencing Rules: SPT

SPT SEQUENCE

START TIME

PROCESSING COMPLETION DUE TIME TIME DATE

TARDINESS

C A E D B

0 2 7 13 21

2 5 6 8 10

2 7 13 21 31

5 10 8 12 15

0 0 5 9 16

Simple Sequencing Rules: Summary

RULE AVERAGE COMPLETION TIME AVERAGE TARDINESS NO. OF JOBS TARDY MAXIMUM TARDINESS

FCFS DDATE SLACK CR SPT

18.60 15.00 16.40 20.80 14.80

9.6 5.6 6.8 11.2 6.0

3 3 4 4 3

23 16 16 26 16

Sequencing Jobs Through Two Serial Process

Johnsons Rule
1. List time required to process each job at each machine. Set up a one-dimensional matrix to represent desired sequence with # of slots equal to # of jobs. Select smallest processing time at either machine. If that time is on machine 1, put the job as near to beginning of sequence as possible. If smallest time occurs on machine 2, put the job as near to the end of the sequence as possible. Remove job from list. Repeat steps 2-4 until all slots in matrix are filled and all jobs are sequenced.

2.

3. 4. 5.

EXAMPLE
JOB A B C D E Work Station 1 6 11 7 9 5 Work Station 2 8 6 3 7 10

DETERMINE THE SEQUENCE TO COMPLETE THE SET OF 5 JOBS AS SOON AS POSSIBLE. CALCULATE FINAL COMPLETION TIME FOR THE SET OF JOBS AND THE IDLE TIME OF EACH M/C CENTRE

Johnsons Rule

JOB A B C D E

PROCESS 1 6 11 7 9 5

PROCESS 2 8 6 3 7 10

Johnsons Rule (cont.)

E
E 5 A 11 D 20

D
B

C
C 31 38
Process 1 (sanding)

Idle time E 5 15 A 23 D 30 B 37 C 41
Process 2 (painting)

Completion time = 41 Idle time = 5+1+1+3=10

JOHNSONS RULE WITH 3 MACHINES There are 5 Jobs, each of which must go through machines M1, M2, M3 in the order M1--> M2 --> M3. Processing times are: Job M1 M2 M3 1 8 6 10 2 5 2 13 3 4 9 11 4 6 7 10 5 5 4 12

JOHNSONS RULE

IF EITHER OR BOTH OF THE FOLLOWING CONDITIONS HOLD THEN THIS PROBLEM CAN BE REDUCED TO THE PROBLEM WITH N JOBS AND 2 MACHINES.
CONDITION 1. Min Mi1 Max Mij for j = 2, m-1 i i CONDITION 2. Min Mim Max Mij for j = 2, m-1 i i

Johnsons Rule (3 M/C)

Condition 2 holds good in this example. Hence, Job 1 2 3 4 5 MF1 14 7 13 13 9 MF2 16 15 20 17 16 The Optimal Sequence: 2 5 4 3 1

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